Method for the production of an outer wall, method for the production of an armored motor vehicle, and side wall for a motor vehicle

ABSTRACT

In a method for producing an outer wall, in particular a side wall for a motor vehicle, from armored steel, having openings, a rocker panel extending in the bottom region, a roof frame area, pillars and side pieces extending between the rocker panel and the roof frame area, and openings for receiving windows, the outer contour of the outer wall is defined, and a pressing tool is provided for forming an outer wall blank having this outer contour. The outer wall blank is formed from an armor steel metal sheet and the doors and the openings are cut out from the outer wall blank.

The present invention relates to a method for producing an outer wall,in particular a side wall for a motor vehicle, from armor steel,comprising openings, a rocker panel running in the bottom region, a roofframe region, pillars extending between the rocker panel and the roofframe region, and side parts, as well as openings for the reception ofwindows.

The invention further relates to a method for producing an armored motorvehicle having an outer wall made of armor steel, in particular a sidewall with doors, which side wall has on a motor vehicle a rocker panelrunning in the bottom region, a roof frame region, pillars extendingbetween the rocker panel and the roof frame region, side parts, andopenings for the reception of windows.

The present invention further relates to a side wall for a motor vehiclemade from armor steel, comprising doors, a rocker panel running in thebottom region, a roof frame region, pillars extending between the rockerpanel and the roof frame region, side parts, and openings for thereception of windows.

Structurally reinforced vehicle side walls, compiled from a plurality ofindividual components, are known from the prior art. In the front doorregion, the vehicle side wall consists, for example, of the A-pillarhaving a rocker panel connection. The B-pillar and the rocker panel areseparate components. The individual components are produced andheat-treated in part in the hot forming process and must in somecircumstances fulfill different material thicknesses and strengthrequirements. Following the production of the individual parts, theseare joined together by spot welding or gluing to a side wall for a motorvehicle. At the joints, stress peaks can arise. For a weldingconnection, material overlaps are necessary. This impacts negatively,however, on a low total vehicle weight.

In addition, vehicle armorings in which the passenger compartment, and,where necessary, a trunk or engine compartment, is ballisticallyprotected against the effect of warfare are known from the prior art.For the fitting of the vehicle armoring, armoring plates are generallyintegrated into the original vehicle body. Thus a door is armored, forexample, by the installation of an armored safety glass and by theinsertion of an armored steel plate into the original vehicle door inthe panel region of the door side wall. A drawback with this productionmethod for a vehicle armoring is that the ballistic protection iscreated solely by the armored steel plates and the armored glass.Various door structure components, such as, for example, the outer doorskin, the door frame or else the window frame are generally maintainedin the factory delivery state of the production vehicle, yet often offerno armoring protection. A vehicle door already has a weight of between20 and 150 kg, which is additionally increased by the armoring measures.

In a further known embodiment, vehicle body outer parts are impartedwith armored steel plates or replaced by these. These vehicles areparticularly conspicuous from the outside, since they have angularcontours. In addition, the externally applied armoring contributes to amore solid appearance. In this embodiment, two drawbacks are known.Firstly, it is undesirable for the armoring of non-military vehicles tobe directly apparent and, secondly, retrofitted armoring componentswhich have been externally applied are imprecisely shaped. It isspecifically, however, the transitional regions from, for example, thedoors of the vehicle to the connecting regions of the body which are ofparticular importance for ballistic protection. In the event ofinadequate covering, pressure waves can here make their way into theinterior and thus inflict injury on the passengers.

The object of the present invention is therefore to provide a methodwith which an armoring of a motor vehicle is matched particularly wellto the outer contour of the motor vehicle, combined with simultaneoushigh ballistic protective effect. It is also an object of the presentinvention to provide a motor vehicle armoring, as well as a method forthe production of the same, which has a particularly high dimensionalaccuracy.

The aforementioned object is achieved according to the invention with amethod for producing an outer wall according to patent claim 1.

The aforementioned object is further achieved by a method for producingan armored motor vehicle according to patent claim 9.

The material part of the object is achieved by a side wall for a motorvehicle made of armor steel and having doors, according to patent claim12.

Advantageous refinements of the inventive concept are a constituent partof the dependent patent claims.

A particular advantage with the inventive method for producing a motorvehicle armored outer wall is that the total weight of the vehicle isreduced, while the ballistic protective effect is the same and/orimproved. In addition, cost savings are achieved in the productionmethod, since complex integrations into pre-existing structures ofvehicle bodies are eliminated. The particular dimensional stability ofthe gap widths in a vehicle outer wall enhances, in turn, the protectionagainst ballistic effects of warfare. Moreover, motor vehicles which areequipped with outer walls produced with a method according to theinvention are not in the panel region externally identifiable asprotection vehicles.

Inventive side walls made of armor steel additionally increase therigidity of the total body. This is of particular importance in the caseof very strong ballistic effects, such as, for example, explosivecharges. A total deformation to the detriment of the passengercompartment is very largely avoided. The body structure of the motorvehicle is reinforced with the outer walls according to the inventionagainst the deformation effect of warfare.

The inventive method for producing an outer wall, in particular a sidewall for a motor vehicle, from armor steel, comprising openings, arocker panel running in the bottom region, a roof frame region, pillarsextending between the rocker panel and the roof frame region, and sideparts, is characterized by the following method steps:

-   -   definition of the outer contour of the outer wall,    -   provision of a pressing tool for the forming of an outer wall        blank having this outer contour,    -   forming of the outer wall blank from an armor steel metal sheet,        and    -   cutting out of the doors and openings from the outer wall blank.

This offers the advantage that the outer contour of the outer wall ofthe motor vehicle can be identically reproduced with the armored outerwall. Consequently, a difference relative to the original productionvehicle is not detectable from the outside.

From the derived outer contour of the outer wall is derived a suitabletool geometry, allowance being made for the degree of shrinkage duringthe hot forming. From this, a pressing tool for forming an outer wallblank having the outer contour can be provided. According to the purposeof use, this pressing tool can hot form various protective materialsfrom temperature ranges above AC₃ into the desired shape. The variousprotective materials are respectively, in the form of an armor steelmetal sheet, reshaped into an outer wall blank.

For the production, a suitable tool geometry and a corresponding tooldesign must be provided, with due regard to suitable tool materials.Particular importance is attached to the large heat quantity of thearmor steel metal sheet. These have anticipated sheet weights rangingbetween 100 and 500 kg. It is necessary to ensure that the heat isreliably evacuated from the sheet metal and the tool, so that hardeningis possible in the forming tool.

In a further method step, it is provided that doors and openings, aswell as openings in the doors, are cut out of the outer wall blank. Aparticularly good dimensional stability is hereby attainable.Consequently, a small gap width ensues.

In a preferred embodiment, the outer contour is defined by determinationof the original motor vehicle outer contour. The determination can herebe undertaken on the basis of CAD data, which are directly provided, forexample, by the vehicle manufacturer. It is also possible for a pointcloud to be generated, which point cloud is then ascribed to a surfacearea. Furthermore, within the determination of the outer structure, anoptical derivation of the original outer contour is conceivable. Theoptical derivation can be generated by partial or complete redesign.

Preferably, the cutting out of the openings is realized by laser beamcutting or water jet cutting. As a result, a particularly highdimensional stability of the openings relative to the cutouts producedby the cutting ensues. A further advantage of laser beam or water jetcutting is that, in the course of the manufacturing process, a presshardening operation is applied, wherein the outer wall blank is alreadyheat-treated before the openings are cut out. The cutting methods of thelaser beam cutting or water jet cutting keep the structuraltransformations at the cutting sites low, so that the ballisticprotection capability of the thereby produced sheet metal components isnot impaired. In addition, it would also be possible within the scope ofthe invention to produce the openings by punching during the productionoperation.

In a further construction variant, hinges and opening means are coupledto the generated cutouts and the cutouts are arranged as doors and flapsin the outer wall. The doors and flaps are here formed by the cutouts.The cutouts themselves are provided with hinges or opening brackets, forexample in the form of door handles, and are arranged, once again, inthe outer wall. As a result of the previously produced cutouts in theform of the doors, a particularly high dimensional stability is ensuredbetween the outer wall and the doors. The gap width is heresubstantially determined by the cutting out process. Possible warping ofthe components by a downstream heat-treatment process is eliminated inthe method according to the invention.

The fitting of the hinges and opening means can here be realized in anintegrally bonded, form-fit or force-locking connection. The connectionof, for example, window frames, or else door inner panel parts, shouldalso be construed within the scope of the invention.

In a particularly preferred embodiment, the gap widths formed betweendoors and outer wall are configured so as to be ballistically secure bycoupling with respectively circumferential overlaps. The overlap canhere be realized, for example, in the form of a stop or acircumferential weld-on plate or similar. The fitting of the stop cantake place from outside or else from inside. The attachment can be madeto the door or to the side wall. It is particularly beneficial that thefitting of the overlap can be realized individually in accordance withthe different armoring level requirements. In the case of highanticipated ballistic pressure effects resulting from explosive warfare,for example, the fitting of an overlap from the outside is thusadvantageous, whereas, in the case of a low level of armoring, theoverlap can be fitted from the inside, so that an appearance of theproduction vehicle which is as true to the original as possible ismaintained.

Within the scope of the invention, the production of the outer wallblank can be realized by means of hot forming or by cold forming. Theforming operations are respectively followed by a heat treatment in theform of hardening of the outer wall blank. This can be realized, forexample, in the hot forming process by quenching in a tool clampingsystem or else by cold forming with subsequent heat treatment. Thisgives the advantage that, according to the material used, the heattreatment process can be individually tailored thereto, so that optimalforming conditions are achieved and an optimal hardening, and thusprotective effect, of the armored material is adjusted in line with therespective requirement profile.

The present invention further relates to a method for producing anarmored motor vehicle having an outer wall made of armor steel, inparticular a side wall with doors, which side wall has on a motorvehicle a rocker panel running in the bottom region, a roof frameregion, pillars extending between the rocker panel and the roof frameregion, and side parts, said method comprising the following methodsteps:

-   -   removal of the original vehicle outer wall,    -   arrangement of the outer wall of armor steel on the motor        vehicle, and    -   coupling of the outer wall to the motor vehicle.

This gives the advantage that the original vehicle outer wall isreplaced by the produced motor vehicle armored outer wall. In terms ofthe vehicle, unnecessary weight which would accrue, for example, fromthe standard sheet metal outer wall with integrated armored steel platesis eliminated. The outer wall of armor steel is thus optimized withregard to the weight distribution and also the weight. Furthermore, anouter wall produced with the method according to the invention can beoptimally integrated onto and into the vehicle. In the roof region, aswell as in the underbody region, it can be coupled to the vehicle,wherein in the roof region and underbody region further armorings areintroduced. Within the scope of the invention, the roof or underbodyregion itself can also be produced with the inventive method forproducing an outer wall.

Preferably, the outer wall is coupled to original connecting points ofthe motor vehicle. Through precise ripping out of the unarmored outerwall, it is possible to produce the connecting region directly withstandard connecting points and the armored outer wall. This offers, inparticular, the advantage that the rigidity of the vehicle body, by theretrofitting of an armored outer wall on the original connecting points,remains equal to the production vehicle, or is enhanced by the armoredcomponent.

In a further embodiment, the outer wall is coupled in a roof region, ina floor region and/or in front regions to additional armored steelplates which are mounted on the motor vehicle for the armoring of theregions. The additional coupling offers on the one hand an enhancementof the ballistic protection, on the other hand an enhancement of therigidity of the total vehicle body.

The present invention further relates to a side wall for a motor vehiclemade of armor steel, comprising doors, a rocker panel running in thebottom region, a roof frame region, pillars extending between the rockerpanel and the roof frame region, and side parts, characterized in thatthe side wall is produced in one piece from an armor steel metal sheet,and the doors and openings are then cut out of the produced shaped part.

In a particularly preferred embodiment, the side wall has a hardnessbetween 300 and 800 Brinell hardness. The armored side wall which isthus produced offers, in particular, protection against warfare in theform of explosive charges and also in the form of projectiles. Accordingto the used armored material and used requirement profile, or therequired level of armoring, said side wall must expediently be tailoredto the wishes of the respective vehicle manufacturer or customer with aproduction method within the scope of the invention.

In another preferred embodiment, a gap, surrounding the doors, betweenthe door and the side part is designed to be ballistically secure byvirtue of additional coupled covers. Pressure waves can hence penetratethrough the gaps into the protected compartment only in reduced form. Asa result of connections with sealing profiles, the protected compartmentcan be protected against nuclear, bacteriological and chemical warfare.

Further advantages, features, characteristics and aspects of the presentinvention emerge from the following description, preferred embodimentson the basis of the schematic drawings. These serve for easierunderstanding of the invention, wherein:

FIGS. 1 a-1 d show an inventive method for producing an armored outerpart;

FIG. 2 shows a sectional view of a transitional region of the outer wallto a door with overlap, and

FIG. 3 shows an inventive construction variant of an armored side partwith doors.

In the figures, the same reference symbols are used for same or similarparts, wherein corresponding or comparable advantages are achieved evenif a repeated description is dispensed with for reasons ofsimplification.

FIGS. 1 a to 1 d show an inventive method for producing an outer wall 1of an armored motor vehicle 2. In a first step, an outer contour 3 ofthe armored motor vehicle 2 is determined. In the determination of theouter contour 3, rocker panels 4, a roof frame region 5, various pillars6, such as, for example, the A, B and C pillar of a side part 7 of anarmored motor vehicle 2, are determined. Following this, openings 8 arefixed in the side wall of the armored motor vehicle 2. With the thusdetermined data, a pressing tool (not detailed here) is provided. In thepressing tool, an armor steel metal sheet is formed into an outer wallblank 9. This is represented in FIG. 1 a. In a second step, cutouts 10are generated in the outer wall blank 9. The cutouts 10 are generated atthe sites at which openings 8 are intended to be formed. The openings 8can be configured, for example, in the form of a window cutout 11, orelse a door 12. The doors 12 themselves can, in turn, have windowcutouts 11.

In a third method step, the cut-out doors 12 are provided with hinges 13and further opening means 14. The coupling to a window frame region (notreferred to in detail here), or else to inner panel parts, should alsobe construed, for example, as an element of the invention. In a fourthstep, represented in FIG. 1 d, the doors 12 coupled to the hinges 13 andopening means 14 are, in turn, inserted into the side part 7. To thisend, the doors 12 with the hinges 13 and with the opening means 14 areconnected to the side wall at coupling points (not shown here due to theschematic drawing). Particularly advantageously, in the method accordingto the invention, an optimal minimal gap width 15 bordering the doors 12is obtained.

In FIG. 2, the transitional region of the side part 7 to a door 12 withan overlap 16 is represented. It is particularly evident that a minimalgap width 15 is configured between the door 12 and the side part 7. Theoverlap 16 offers, on the one hand, supplementary ballistic protection,on the other hand, however, also a stop facility for the door 12. Theoverlap 16 can here be coupled in a connecting region to the door 12, orelse, as represented here, to the side wall. The coupling is preferablyrealized in an integrally bonded connection, but can also be realized inform-fit and/or force-locking connection. There is also the option offitting a seal circumferentially to the door 12 in the region of theconnecting region 17. The seal 18 can also, however, be fitted to theoverlap 16.

FIG. 3 shows an inventive construction variant of an armored vehicleouter wall 19 with doors 12. The vehicle outer wall 19 is produced withthe inventive method for producing an armored outer wall with doors 12,and is coupled to the armored motor vehicle 2 at factory-made connectingpoints 20. The coupling is here realized in a roof region 21, in a floorregion 22 and in a front region 23. At the respective coupling regions,the motor vehicle 2 can be reinforced with additional armor steel plates24.

REFERENCE SYMBOLS

-   -   1—outer wall    -   2—armored motor vehicle    -   3—outer contour    -   4—rocker panel    -   5—roof frame region    -   6—pillar    -   7—side part    -   8—opening    -   9—outer wall blank    -   10—cutout    -   11—window cutout    -   12—door    -   13—hinge    -   14—opening means    -   15—gap width    -   16—overlap    -   17—connecting region    -   18—seal    -   19—vehicle outer wall    -   20—connecting point    -   21—roof region    -   22—floor region    -   23—front region    -   24—armor steel plate

1.-14. (canceled)
 15. A method for producing an outer wall, comprising: defining an outer contour of an outer wall by determining the disposition of an opening, a rocker panel in a bottom region, a roof frame region, pillars extending between the rocker panel and the roof frame region, and side parts; forming an outer wall blank from an armor steel metal sheet in correspondence with said outer contour, using a pressing tool; and cutting out the opening from the outer wall blank commensurate with the establishment of a door, thereby producing a cutout.
 16. The method of claim 15, wherein the outer wall is a side wall for a motor vehicle.
 17. The method of claim 15, wherein the outer contour is defined by determination of an original motor vehicle outer contour.
 18. The method of claim 15, wherein the outer contour is defined in at least one of two ways, a first way in which the outer contour is optically modeled on a motor vehicle outer contour, a second way in which the outer contour is redesigned.
 19. The method of claim 15, wherein the openings are cut out by laser beam cutting or water jet cutting.
 20. The method of claim 15, further comprising attaching hinges and opening hardware to the cutout, and arranging the cutout as a door in the outer wall.
 21. The method of claim 20, further comprising attaching a circumferential overlap to ballistically secure a gap width formed between the door and the outer wall.
 22. The method of claim 15, wherein the outer wall blank is formed by hot forming or cold forming, with subsequent hardening.
 23. The method of claim 15, further comprising hardening the outer wall blank in the pressing tool.
 24. A method for producing an armored motor vehicle having an outer wall made of armor steel, comprising: removing an original outer wall of the motor vehicle; arranging an outer wall of armor steel on the motor vehicle; and coupling the outer wall to the motor vehicle.
 25. The method of claim 24, wherein the outer wall is a side wall of the armored motor vehicle having a door and including a rocker panel in a bottom region, a roof frame region, pillars extending between the rocker panel and the roof frame region, and side parts.
 26. The method of claim 24, further comprising coupling the outer wall of armor steel to original connecting points of the motor vehicle.
 27. The method of claim 25, further comprising mounting an additional armor steel plate in at least one region of the side wall selected from the group consisting of roof region, floor region, and front region, and coupling the side wall in the region to the additional armor steel plate.
 28. A side wall for a motor vehicle made in one piece from an armor steel metal sheet to produce a shaped part and comprising a rocker panel running in a bottom region, a roof frame region, pillars extending between the rocker panel and the roof frame region, and a side part, with an opening being cut out commensurate with the establishment of a door in the shaped part.
 29. The side wall of claim 28, having a hardness between 300 and 800 HB.
 30. The side wall of claim 28, further comprising an additional cover to ballistically secure a gap which surrounds the door and is formed between the door and the side part. 